Method for making envelope containing return envelope structure

ABSTRACT

AN ENVELOPE ASSEMBLY COMPRISING A MAIN ENVELOPE AND A RETURN ENVELOPE STRUCTURE CONTAINED IN SAID MAIN ENVELOPE AND MADE FROM TWO CONTINUOUSLY MOVING WEBS OF SHEET MATERIAL. A PARTIALLY FOLDED RETURN ENVELOPE STRUCTURE WHICH INCLUDES A RETURN ENVELOPE STRUCATTACHED COUPONS IS CUT FROM ONE WEB AND POSITIONED ON AN ASSOCIATED MAIN ENVELOPE BLANK CUT FROM THE OTHER WEB AND MOVING IN SYNCHRONISM THERWEITH. THE MAIN ENVELOPE BLANK AND THE RETURN ENVELOPE STRUCTURE ARE SIMULTANEOUSLY FOLDED ONTO THEMSELVES ALONG AT LEAST ONE COMMON FOLD LINE AND ASSOCIATED MARGINAL PORTIONS OF THE BLANK ARE CONNECTED IN FACE-TO-FACE RELATION TO FORM A MAIN ENVELOPE POCKET CONTAINING THE RETURN ENVELOPE STRUCTURE. THE NAME AND ADDRESS OF THE RECIPIENT IS IMPRINTED ON THE RETURN ENVELOPE THROUGH A WINDOW IN THE MAIN ENVELOPE. THE RETURN ENVELOPE MAY BE OF OPEN-SIDE OR OPENEND TYPE.

Nov. 9, 1971 r w. H. GENDRON 3,618,284

METHOD FOR MAKING ENVELOPE CONTAINING RETURN ENVELOPE STRUCTURE Filed March 23 1970 2 Shpets-Sheat l /0 f8 72 Z2 M 70 zz all/2% g Q I 2U 24 1v a I [m l 3 /70 22 /6 4 /6 INVENIOR. WILFRED H. GENDRON aid/(1Q ATM/VETS Nov. 9, 1971 w. H. GENDRON 3,618,284

METHOD FOR MAKING ENVELOPE CONTAINING RETURN ENVELOPE STRUCTURE .Filed March 23 1970 2 Sheets-Shoat 2 NAME ADDRESS United States Patent 3,618,284 OD FOR MAKING ENVELOPE CONTAINING METH RETURN ENVELOPE STRUCTURE Wilfred H. Gendron, Wilbraham, Mass, asslgnor to United States Envelope Company, Springfield, Mass. Filed Mar. 23, 1970, Ser. No. 21,926 Int. Cl. B65b 35/50, 61/26, 63/04 US. Cl. 5323 15 Claims ABSTRACT OF THE DISCLOSURE An envelope assembly comprising a main envelope and a return envelope structure contained in said mam envelope and made from two continuously moving webs of sheet material. A partially folded return envelope structure which includes a return envelope and one or more attached coupons is cut from one web and positioned on an associated main envelope blank cut from the other web and moving in synchronism therewith. The main envelope blank and the return envelope structure are simultaneously folded onto themselves along at least one common fold line and associated marginal portions of the blank are connected in face-to-face relation to form a main envelope pocket containing the return envelope structure. The name and address of the recipient is imprlnted on the return envelope through a window in the mam envelope. The return envelope may be of open-s1de or openend type.

BACKGROUND OF THE INVENTION This invention relates in general to a method for making envelope assemblies and deals more particularly with an improved method for making web cut envelope assemblies which comprise a main envelope containing a return envelope structure, which includes a return envelope and one or more detachable coupons or the like.

Envelope assemblies made in accordance w th the present invention are particularly adapted for use in business reply or as direct mail specialties, where a complete mailing package is desired. The general aim of. the present invention is to provide improved methods for high speed web fed production of envelope assemblies of the aforedescribed type.

SUMMARY OF THE INVENTION In accordance with the present invention, envelope assemblies are formed by continuously advancing two webs of sheet material, folding and cutting one of the webs to form a partially folded return envelope structure, cutting a main envelope blank from the other of the webs and advancing it in synchronism with the webs, POSltlOIllIlg the partially return envelope structure on the main envelope blank, simultaneously folding the blank and the return envelope structure onto themselves along at least one common fold line, and joining associated marginal portions of the main envelope blank in face -to-face relation to form a main envelope pocket contaimng a completely folded return envelope structure.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a frontal view of an envelope assembly made in accordance with a method of the present invention, portions of the assembly being shown broken away.

FIG. 2 is a rear view of the envelope assembly of FIG. 1.

FIG. 3 is a rear view of the return envelope structure of FIG. 1 shown in an open or unfolded condition.

FIG. 4 is a somewhat reduced plan view of a web of sheet material, showing, from left to right, successive 3,618,284 Patented Nov. 9, 1971 changes in the material as a return envelope structure is formed therefrom.

FIG. 5 is a somewhat reduced plan view of another web of sheet material, showing, from left to right, successive changes in the material as a main envelope blank is formed therefrom and a return envelope structure is joined therewith to form the envelope assembly of FIG. 1.

FIG. 6 is similar to FIG. 1 but shows another envelope assembly made in accordance with another method of the present invention.

FIG. 7 is a rear view of the envelope assembly of FIG. 6.

FIG. 8 is a rear view of the return envelope structure of FIG. 6 shown in an open or unfolded condition.

FIG. 9 is a somewhat reduced plan view of still another web of sheet material, showing, from left to right, successive changes in the material as the return envelope structure of FIG. 8 is formed therefrom.

FIG. 10 is a somewhat reduced plan view of yet another web of sheet material, showing, from left to right, successive changes in the material as a main envelope blank is formed therefrom and a return envelope structure is joined therewith to form the envelope assembly of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Turning now to the drawings, and referring particularly to FIGS. 1 and 2, an envelope assembly made in accordance with a method of the present invention and indicated generally at 10 comprises a main envelope 12 and a return envelope structure 14 contained therein. The main envelope 12 is a seamless envelope of open-side type, that is, one which has a mouth opening along its longest dimension. It is formed from a unitary blank and includes front and back panels, respectively, indicated at 16 and 18 connected together along a lower fold line 20 and joined in face-to-face relation at the side edges thereof along lines of attachment defined by lines of adhesive 22, 22. A generally chevron-shaped closing or sealing flap 2'4 connected to the front panel 16 along an upper fold line 26 overlies an associated portion of the back panel 18 in a closed position and is sealed thereto along another line of adhesive '28. Preferably, and as shown, the envelope 10 also includes a window 30 formed in the front panel 16 and opening therethrough.

The return envelope structure 14, as oriented in FIG. 3, includes a seamless return envelope 32 of open-end type, that is, one which has a mouth opening along its shortest dimension. It has a front panel 34 and a rear panel 36 connected at one side edge along a fold line 38 and joined together in face-to-face relation at the upper and lower edges thereof by lines of adhesive 40, 40. The envelope 14 also includes a closing or sealing flap 42 connected to one side edge of the front panel 34 along a fold or score line 44. A line of adhesive 46 carried by the sealing flap may be used to seal it in a closed position when it is folded into overlying relation with the back panel 36. The reply envelope structure 14 also includes another panel or coupon 48 formed by an extension of the front panel 34 and separated from the envelope 32 by a line of weakening or perforation 50. Another panel or coupon 52 is connected to the coupon 48 along another line of weakening or perforation 54 aligned with the fold line 38. The reply envelope structure 14 is shown in its unfolded or open condition in FIG. 3. However, when the structure 14 is positioned in the main envelope 12 the panel 48 is folded along the line of perforation 50 and overlies the envelope front panel 32 and the coupon 52 is folded along the line of perforation :54 and overlies the coupon 48. The name and address of the recipient printed on the exposed surface of the back panel 36 is visible through the window 30 when the return envelope structure 14 is positioned in the main envelope.

The envelope assembly is particularly adapted to be made on a conventional high-speed envelope making machine of a type capable of simultaneously and continuously advancing two webs of sheet material while simultaneously performing a series of gluing, cutting, folding and joining operations thereon. Referring now to FIGS. 4 and 5, successive steps for forming an envelope assembly 10 in accordance with the preferred method of the present invention are illustrated with reference to fragmentary portions of two elongated webs of sheet material 56 and 58, respectively, corresponding to upper and lower webs of material advancing in a longitudinal direction or from left to right in a typical envelope making machine (not shown). While the sequence in which the various operations are performed may vary, a preferred sequence is illustrated.

Considering first a preferred method for making the return envelope structure 14 and referring to FIG. 4, the upper web 56 is advanced in a longitudinal direction while a plurality of gumming, cutting, folding and joining operations are simultaneously performed on associated portions of the web at various machine stations. The forward end portion of the web is folded onto itself to form a lower ply 60 and an upper ply 62 connected to one side edge of the lower ply along the longitudinally extending fold line 38. The upper ply 62 is somewhat wider than the lower ply 60 and includes a marginal portion 64 adjacent its free side edge which extends transversely beyond the free side edge of the lower ply 60.

Each envelope 32 is formed by connecting associated portions of the two plies in face-to-face relationship along a pair of longitudinally spaced apart and transversely extending lines of attachment defined by the lines of adhesive indicated at 40, 40. The adhesive may, for example, be of a pressure sensitive or remoistenable type and, as shown, is applied to one of the plies before the web 56 is folded. Another line of adhesive 46 which extends longitudinally along the marginal edge portion 64 between each pair of lines of adhesive 40, 40 is preferably applied to the web 56 when the lines 40, 40, are applied thereto. A line of separation 66 which ultimately separates the coupon 52 from the envelope back panel 36 is cut through the lower ply 60 and extends from the fold line 38 to the free edge of the lower ply. The line of weakening or perforation 50 which is formed on the upper ply 62 extends from the fold line 38 to the free edge of the upper ply generally adjacent a line of adhesive 50 and in general transverse alignment with the line of separation 66. The line of weakening 54 which ultimately separates the panels 48 and 52, as shown in FIG. 3, is also formed on the web 56 coincident with an associated portion of the fold line 38, as shown. After the web 56 has been folded onto itself and associated portions of the two plies have been joined to form a return envelope pocket therebetween. Each return envelope structure 14 which includes an associated return envelope 32 and attached coupons 48 and 52 is separated from the web 56 by cutting the web along a generally transversely extending line of separation 68.

The main envelope 14 is folded from a blank 69 cut from the advancing web 58 as shown in FIG. 5. The web 58 is out along a generally chevron-shaped line of separation 70 so that the leading or advancing edge of one envelope blank 69 and the trailing edge of the next successive blank 69 are simultaneously formed. The window is also preferably cut in the advancing web at this time. Lines of adhesive 22, 22 are applied near the opposite side edges of the blank 69 as it advances in synchronism with the webs 56 and 58. One or more spots of adhesive such as indicated at 72, 72 may, if desired, also be applied to the blank 69 at this time. The adhesive applied at 72, 72 is preferably a release type adhesive used to temporarily secure the return envelope structure 14 to the main envelope blank 69 during manufacture but which will readily release to permit removal of the return envelope structure from the main envelope without risk of tearing or otherwise damaging the structure.

The partially folded return envelope structure 14 is positioned on the advancing blank 69 to overlie an associated portion thereof. When the blank 69 is provided with a window 30 the return envelope structure is positioned so that the back panel 32 thereof covers the window opening. The return envelope structure 14 is, or may be, adhered to the blank 69 by spots of adhesive 72, 72. The blank 69 and the return envelope structure 14 are simultaneously folded onto themselves along a common fold line 20 so that the main envelope front and back panels 16 and 18 are formed which are connected along the common fold line with the return envelope structure 14 folded therebetween along the line of weakening 50. Thereafter, the marginal portion of the main envelope front and rear panels 16 and 18, respectively, are connected together in face-to-face relation to form a main envelope pocket which contains the completely folded return envelope pocket which contains the completely folded return envelope structure. The main envelope closing flap 24 may, if desired, be folded to and sealed in its closed position by the envelope making machine. The address of the recipient may, if desired, be imprinted on the return envelope rear panel 32 through the window opening 30 after the envelope assembly 10 has been completed. The return envelope front panel 34 may carry return postage and also have the name and address of the sender imprinted thereon. Thus, the envelope assembly 10 comprises a complete mailing package which may include a fully addressed return envelope and one or more coupons which may, for example, comprise order blanks or the like, for return mailing.

Another envelope assembly made in accordance with the present invention is illustrated in FIGS. 6-8 and designated generally by the reference numeral 100. Parts of the structure 10a which correspond to parts of the assembly 10 previously described bear the same reference numerals and a letter a suffix and will not be hereinafter described in detail.

The assembly 10a differs from the assembly 10 in the construction and arrangement of its return envelope structure 14a, best shown in FIG. 8. More specifically, the return envelope structure 14a includes a seamless return envelope 32a of open side type which has coupons 48a and 52a attached thereto. The envelope 32a has a front panel 34a and a rear panel 36a connected to an associated side edge of the front panel along a fold line 38a. The front and rear panels are joined together in face-to-face relation along lines of attachment defined by a line of adhesive 74 which extends along the bottom edge of the panels and another line of adhesive 76 which extends upwardly from the line 74 along the other side edge of the panels. A closing flap 42a is connected to the front panel 34a along a fold or score line 44a and carries another line of adhesive 46a for connecting the flap in sealing engagement with the rear panel 36a when it is folded to a closed position overlying an associated portion of the latter panel. The coupon 48a formed by an extension of the front panel 34a is separated therefrom by a line of perforation 50a. The other panel or coupon 52a is connected to the coupon 48a along a line of perforation 54. When the return envelope structure 14a is in its fully folded condition in the main envelope pocket the panel 48a is folded along the line of perforation 50a and overlies the front panel 34a, the coupon 52a is folded along the line of perforation 54a and overlies the coupon 48a, and the closing flap 42a is folded along the fold line 44a and overlies an associated portion of the coupon 52a.

The return envelope structure 14a is made from an elongated web of sheet material 5611 folded onto itself along a longitudinally central fold line 38a to form a lower ply a and an upper ply 62a connected to one side edge of the lower ply along the fold line 380. Each return envelope 32a is formed by joining associated portions of the two plies in face-to-face relation along two lines of attachment defined by the lines of adhesive 74 and 76 applied to one of the plies before the web 56a is folded. As shown, the line of adhesive 74 extends transversely of the upper ply 62a between the fold line 38a and the free edge of the ply. The other line of adhesive 74 extends for some distance along the free edge of the upper ply from the line of adhesive 74. The line of adhesive 46a is also applied to the upper ply 62a and extends transversely thereof between the fold line 38a and the free edge of the ply in longitudinally spaced relation to the free end of the line of adhesive 76. The line of perforation 50a is formed on the upper ply and extends from the fold line 38a to the free edge of the ply generally adjacent the line of adhesive 74. The line of perforation 54a is also formed on the web 56a and preferably coincides with an associated portion of the fold line 38a. The lower ply 60a is out along a line of separation 66a which extends transversely of the ply in general alignment with the line of weakening 50a to separate the portion of the lower ply which forms the rear panel 3 6a from the remaining portion of the ply. The envelope closing flap 42a is formed by cutting a transversely extending portion 78 from the lower ply longitudinally spaced from the line of separation 66a and generally opposite the line of adhesive 46a. When the two plies 60a and 62a are folded into face-to-face relation and joined, an envelope pocket is formed between the plies and further defined by a portion of the fold line 38a and the lines of adhesive 74 and 76. Each return envelope structure 14a which includes a pocket is separated from the web 56a by cutting the web along a generally transversely extending line of separation 68a.

A main envelope blank 69a is formed from another web 58a in the manner generally aforedescribed with reference to the blank 69. As the blank 69a is advanced in synchronism with the web 56a and 58a a partially folded return envelope structure 14a is positioned thereof and may, if desired, be temporarily secured thereto by spots of adhesive 72a, 72a. Assembly of the main envelope 12a and folding of the return envelope structure 14a is completed by folding the main envelope blank 69a and the return envelope structure 14a onto themselves along common fold lines. The blank and return envelo e structure are first folded along a common fold line 20a. Associated marginal portions of the blank 6% are then connected together by the lines of adhesive 22a, 22a so that the main envelope front and rear panels 34a and 36a are formed with the folded return envelope structure 14a disposed therebetween. Thereafter, the main envelope blank 69a and the return envelope structure 14a are folded onto themselves along another common fold line 80 to effect simultaneous formation of the main envelope closing flap 24a and the return envelope closing flap 42a. It will be noted that in the latter folding operation the closing flap 24a is folded to its closed position and the return envelope closing flap 42a is simultaneously folded into overlying relation with an associated portion of the return envelope front panel 36a. The main envelope closing flap 24a may, if desired, be sealed in its closed position by the envelope making machine. The machine may also be arranged to imprint the address of the recipient on the return envelope rear panel 36a through the window 30a.

What is claimed is:

1. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope comprising the steps of continuously advancing two elongated webs of sheet material in a longitudinal direction, cutting one of said webs to separate therefrom a main envelope blank, advancing said blank in synchronism with said webs, folding the other of said webs onto itself along a longitudinally extending fold line to form an upper ply and a lower ply connected to said upper ply along said longitudinally extending fold line,

joining associated portions of said upper and lower plies in face-to-face relation to form return envelope front and back panels having a return envelope pocket therebetween, cutting said other web to separate therefrom a partially folded return envelope structure including said return envelope pocket, positioning said partially folded return envelope structure on said advancing blank in overlying relation with a portion thereof, simultaneously folding said return envelope structure and said blank onto themselves along at least one common fold line to complete the folding of said return envelope structure and to form from said blank'main envelope front and back panels connected together along said one common fold line with said return envelope structure therebetween, and connecting associated marginal portions of said main envelope front and back panels in face-to-face relation to form a main envelope pocket containing said return envelope structure.

2. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 including the additional step of cutting a window in said main envelope blank before positioning said return envelope structure thereon, wherein the step of positioning is further defined as positioning said return envelope structure on said advancing blank to cover said window, and including the additional step of imprinting on said return envelope structure through said window.

3. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 including the additional step of simultaneously folding said main envelope blank and said return envelope structure onto themselves along another common fold line to form a main envelope closing flap connected to one of said main envelope panels along said other common fold line and a return envelope closing fiap connected to one of said return envelope panels along said other common fold line.

4. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 wherein thestep of joining associated portions is further defined as joining associated portions of said upper and lower plies in faceto-face relation along two lines of attachment to form a return envelope pocket therebetween defined by said return envelope front and back panels, said two lines of attachment and a portion of said longitudinally extending fold line.

5. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 4 including the step of applying lines of adhesive to a portion of said other web comprising one of said plies before the step of folding said other web along said longitudinally extending fold line, said lines of adhesive comprising said lines of attachment.

6. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 4 wherein the step of joining said plies along two lines of attachment is further defined as joining said plies along two longitudinally spaced apart and generally transversely extending lines of attachment.

7. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 4 wherein the step of joining said plies along two lines of attachment is further defined as joining said plies along one line of attachment extending generally transversely between said longitudinally extending fold line and the longitudinally extending free edge of one of said plies and along another line of attachment extending in a longitudinal direction from said one line of attachment near said free edge.

8. A method for simultaneously forming a main envelope structure contained in said envelope as set forth in claim 4 including the additional step of cutting one of said plies along a line of separation to separate the portion of said one ply comprising one of said return envelope panels from the remaining portion of said one ply.

9. A method for simultaneously forming a main envelope and a return envelope contained in said main envelope as set forth in claim 8 including the additional step of cutting a portion from one of said plies spaced from said line of separation.

10. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 8 including the additional step of forming a line of weakening on the other of said plies to separate the portion of said other ply comprising the other of said return envelope panels from the remaining portion of said other ply.

11. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 10 including the additional step of forming at least one other line of weakening on said other'web to divide said remaining portions thereof into at least tWo parts.

12. A method for simultaneously forming a main envelope and a return envelope structure as set forth in claim 11 wherein the step of forming said one other line of weakening is further defined as forming said one other line of weakening coincident with an associated portion of said longitudinally extending fold line.

13. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 wherein said return envelope structure includes a return envelope and at least one coupon attached to said return envelope and the step of cutting said other Web is further defined as cutting said other web along a generally transversely extending line of separation.

14. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 including the steps of applying at least one spot of adhesive to said blank before said step of positioning said reutrn envelope and wherein said step of positioning is further defined as positioning said return envelope on said blank in overlying relation to said spot to temporarily secure said return envelope structure to said blank.

15. A method for simultaneously forming a main envelope and a return envelope structure contained in said main envelope as set forth in claim 1 wherein the step of folding the other of said webs is further defined as folding the other of said Webs onto itself along a longitudinally extending fold line so that a longitudinally extending marginal portion of one of said plies is exposed transversely beyond the longitudinally extending free edge portion of the other of said plies and including the additional step of applying a line of adhesive to said exposed marginal portion.

References Cited UNITED STATES PATENTS R. 25,961 2/1966 Volks 53-206 1,115,600 11/1914 Shrady 53-206 X 1,636,495 7/1927 Widmaier 93-63 M 1,700,050 1/1929 Henderson 53-23 X 1,865,037 6/1932 Novick 93-35 MW 1,944,794 1/1934 Klinger 93-63 M 1,958,005 5/1934 Klinger 93-61 A 2,342,198 2/1944 Hultin 93-56 PD 3,380,648 4/1968 De Lyra 93-61 A 3,382,778 5/1968 Berkowitz 93-61 A 3,457,696 7/1969 Berkley 53-206 X FOREIGN PATENTS 807,026 1/1959 Great Britain 93-56 PD WAYNE A. MORSE, JR., Primary Examiner US. Cl. X.R.

53-21 FW, 131, 158; 93-56 PD, 61 A, 63 M, 73 

